APM 3DLevelScanner II Documentation Kit

Documentation

Kit

Changing the market

from level to volume

3DLevelScanner

TM

II

3DLevelScanner

TM

II

HT

Kit Content:

• HardwareManual

• cFMusControlDrawing

• ATEXSafetyManual

Contents

1 ABOUT THIS DOCUMENT ........................................................................................ 3

1.1 SYMBOLS IN USE ........................................................................................................ 3

1.2 FOR YOUR SAFETY ...................................................................................................... 3

1.3 STORAGE AND TRANSPORT........................................................................................... 4

2 3DLEVELSCANNERᵀᴹ OVERVIEW ............................................................................ 5

2.1 THEORY OF OPERATION .............................................................................................. 5

2.2 WIDE APPLICATION RANGE ......................................................................................... 5

2.3 ADVANTAGES ............................................................................................................ 5

2.4 MODELS .................................................................................................................. 6

3 PHYSICAL INSTALLATION ........................................................................................ 7

3.1 LOCATION AND POSITIONING GUIDELINES ....................................................................... 7

3.2 SCANNER ORIENTATION .............................................................................................. 9

3.3 SITE PREPARATIONS ................................................................................................. 10

3.4 ASSEMBLY AND MOUNTING ....................................................................................... 11

3.5 WIRING ................................................................................................................. 14

4 FIRST-TIME ACTIVATION ...................................................................................... 18

4.1 LOCAL USER INTERFACE ............................................................................................ 18

4.2 SWITCHING ON THE SCANNER ..................................................................................... 19

4.3 FIRST-TIME ACTIVATION STEPS SUMMARY .................................................................... 20

4.4 INITIAL SETUP PROCEDURE ......................................................................................... 20

5 DIFFERENT CONNECTION METHODS .................................................................... 21

5.1 4-20MA CONNECTION ............................................................................................. 21

5.2 HART COMMUNICATION .......................................................................................... 21

5.3 RS485 COMMUNICATION ......................................................................................... 22

5.4 COMMUNICATION USING THE 3DLINKPRO ................................................................... 22

5.5 TCP/IP COMMUNICATION ........................................................................................ 22

APPENDIX A: ONBOARD CONFIGURATION .................................................................. 23

OUTPUT SETTINGS .............................................................................................................. 23

DISPLAY SETTINGS .............................................................................................................. 24

DEVICE INFO ...................................................................................................................... 27

DEVICE RESET .................................................................................................................... 28

APPENDIX B: ACCESSORIES .......................................................................................... 29

INSTALLATION FLANGES ....................................................................................................... 29

NECK EXTENSIONS .............................................................................................................. 31

HEAD-BODY SEPARATION ..................................................................................................... 32

CABLE EXTENSION .............................................................................................................. 33

CABLE GLANDS .................................................................................................................. 33

APPENDIX C: MAINTENANCE ....................................................................................... 34

APPENDIX D: RECOMMENDED TOOLS ......................................................................... 35

APPENDIX E: SPECIFICATIONS ...................................................................................... 36

TECHNICAL DATA ................................................................................................................ 36

DIMENSIONS ..................................................................................................................... 39

APPENDIX F: RMA PROCEDURE ................................................................................... 41

RETURN MATERIAL AUTHORIZATION POLICY ............................................................................ 41

APPENDIX G: STANDARDS & APPROVALS .................................................................... 43

1 About this Document

This operation manual provides detailed product related information, installation, setup and

operation instructions for 3DLevelScanner models S, M and MV. The manual is designed

for trained personnel. Please read it entirely and carefully before unpacking and

installation of the products.

1.1 Symbols in use

The following symbols indicate different sections of additional information as

follows:

IMPORTANT: An indication for additional information, tips, hints or an indication

of helpful additional knowledge.

WARNING: Indication of a potentially dangerous situation, which could result in

serious injury to persons and/or damage to the 3DLevelScanner.

EX APPLICATION: An indication of special instructions relevant to installations

in hazardous locations.

1.2 For your safety

Authorized personnel

All operations described in this manual must be carried out by authorized, trained

personnel only. For safety and warranty reasons, any internal work on the scanners must

be carried out by manufacturer-authorized personnel only.

Warning about misuse

Inappropriate or incorrect use of the scanner may result in hazards and application-specific

malfunctioning such as vessels overfill or damage to system components through incorrect

mounting or adjustments.

If the 3DLevelScanner is used in a manner not specified in this manual, the protection

provided by the 3DLevelScanner will be impaired.

About this Document ● Storage and transport

General safety instructions

The 3DLevelScanner is a high-tech device requiring strict observance of standard

regulations and guidelines. The user must strictly follow the safety instructions in this

operating manual. Local and national electrical codes and all common safety regulations

and accident prevention rules should be considered during installation as well.

CE conformity

The 3DLevelScanner conforms to CE's EMC and NSR standards. CE conformity is as

follows:

EMC

 EN 61326-1: 2006

 CISPR 11: 2003 Class A

 IEC 61000-4-2: 2001 Air Discharge, 8kV

 IEC 61000-4-3: 2002 80-1000MHz, 1V/m; 1.4-

2GHz, 1V.m;

2.0-2.7GHz, 1V/m

 IEC 61000-4-4: 2004 Power Lines: 1kV; Signal Lines: 0.5kV

 IEC 61000-4-6: 2004 0.15-

80MHz 1VRMS, 80% A.M. by

1kHz Power & Signal Lines

NSR

(73/23/EWG)

 EN 61010-1: 2001

FCC conformity (EMC)

FCC Part 15, Sub-part B, Class A.

Safety information for Ex Areas

EX-AREAS: Please note the Ex-specific safety information for installation and

operation in Ex areas. These safety instructions are part of the operating

instructions manual that comes with Ex-approved scanners.

WARNING: Substitution of components may impair Intrinsic Safety.

WARNING: For preventing ignition of flammable or combustible atmospheres,

read, understand and adhere to the manufacturer’s live maintenance procedures.

1.3 Storage and transport

The scanner is protected by special packaging during transport, and is guaranteed to

handle normal loads during transport.

2 3DLevelScannerᵀᴹ Overview

2.1 Theory of Operation

The APM 3DLevelScanner™ is the only device available which delivers accurate

measurement of bulk solids and powders – regardless of material type, product

characteristics, storage silo type, size, bin or container, and harshness of the storage

environment. The product incorporates APM's unique dust-penetrating technology to

achieve an unrivalled degree of process measurement and inventory control.

The 3DLevelScanner™ includes an array of three antennas that generate low frequency

acoustic signals and receive echo signals from the contents of the silo, bin, or other

container type. Using these antennas, the unit measures not only the time/distance of

each echoed signal but also its direction.

The built-in Digital Signal Processor digitally samples and analyses the echoed signals

and produces accurate measurements of the level, volume, and mass of the stored

contents, and generates a 3D representation of the position and form of the material within

the container for displaying on remote computer screens.

2.2 Wide Application Range

The 3DLevelScanner™ measures practically any kind of solid material, stored in variety of

containers, including large open bins, bulk solid storage rooms, stockpiles and

warehouses, mapping loads that randomly form over time inside silos, and many other

challenging applications that were not possible until now. The sensor can measure ranges

of up to 70m (230ft) and generate 3D mapping of the material surface.

2.3 Advantages

 Service and maintenance-friendly - Non-contact measuring principles, the

3DLevelScanner™ is highly easy to service and maintain

 The only available device for solid volume measurement applications

 The only available device that measures minimum and maximum levels

 Suitable for measuring all solid materials (including ones with low dielectric constants)

 Operates in dusty and moisture environments

 Profiles of adhesions of materials to vessel walls

 Self-cleaning antenna

3DLevelScannerᵀᴹ Overview ● Models

 3-Dimensional mapping visualization tool for filling-point choosing assistance (in

vessels with multiple filling points)

 The most reliable sensor available - includes 3 transmitters and 3 receivers

2.4 Models

The 3DLevelScanner™ line of products is consisted of three models: S, M and MV.

Model S

The S model determines the average level of the stored contents and average distance

from the scanner to the surface of the material. Based on a 30° beam angle, The S model

is ideal for small and narrow vessels of up to 4m (13ft) in diameter.

Model M

The M model yields highly accurate readings of level and volume. It is appropriate for large

vessels of up to 15m (50ft) in diameter and at least twice as high (30m / 100ft), open bins

and stockpiles. It is based on a 70° beam angle. The M model also presents the minimum

and maximum Level/Distance measurements along with the calculated average.

Model MV

The MV model is identical to the M model, with the additional capability of generating a 3-

dimensional representation of the stored contents on a remote computer. This feature is

highly useful for mapping build-up loads that form randomly over time and other

irregularities.

All three models are available in various modes, such as ATEX approved, FM approved,

and non-ATEX (for more information, see Approvals on page 38) and also available with

neck extension (see Appendix B: Accessories: Neck on page 31) and compatible with the

Head-Body separation kit.

Each of the models is available in two temperature ranges:

3DLevelScanner II is compatible in applications where the maximal temperature in the

surroundings inside the vessel is up to 85°C (185°F).

3DLevelScanner II HT is compatible in applications where the maximal temperature in the

surroundings inside the vessel is up to 180°C (356°F).

All references in this manual to the 3DLevelScanner can be referred to as

3DLevelScanner or simply the scanner, if nothing else is mentioned it applies to any of the

scanner’s models.

3 Physical Installation

This chapter describes the necessary steps for proper installation of the 3DLevelScanner

beginning with important pre-installation considerations such as environmental conditions,

correct positioning and orientation, through the mounting and configuration process.

3.1 Location and positioning guidelines

Choosing the proper location to the 3DLevelScanner™ should consider every aspect of

the vessel and contained materials, including the silo or vessel dimensions, type of

material and angle of repose, locations of filling and emptying points, maximum level of

material, internal construction and moving part and any other consideration which may

possibly affect the scanner performance. APM strongly recommends installing the

3DLevelScanner according to the 3DScanner Locator PC software for properly choosing

installation location and positioning. In case of no satisfying software solution, please

contact APM Customer Support for assistance with the positioning.

Moisture and water condensation

Use the recommended cable gland and tighten the cable connection. For

additional protection against moisture, lead the connection cable downward in

front of the cable entry. Rain and condensation water can thus drain off. This

applies mainly to mounting in areas where moisture is expected (e.g., by cleaning

processes), or on cooled or heated vessels.

Measuring range

The measuring range is set in the scanner and defined by silo dimensions and the full and

empty calibration levels. These levels set the 100% and 0% values relatively.

The scanner measurements are calibrated to the top of the

body. If the scanner is lowered, or mounted with neck

extension or head-body separation, it is important to adjust

all measurements to the top of the body.

NOTE: If the material level reaches the antenna,

build up could form inside the horn over time and

cause measurement errors or damage to the

membranes.

NOTE: the 3DLevelScanner™ has a 500mm (20”)

of dead zone (or blanking zone).

Physical Installation ● Location and positioning guidelines

Pressure

The process fitting must be sealed in the case of a low pressured vessel. Before usage,

verify that the sealing material is resistant to the stored medium. The maximum allowed

pressure (stated in page 36: Appendix E: Specifications) is indicated on the type label of

the sensor.

Installation location

Choosing the proper installation location for the 3DLevelScanner is an important part of

the installation process. A Wrong location may result in erroneous measurements or loss

of performance.

The usage of the 3DScanner Locator Software is recommended for finding the optimal

location, which is based on various parameters.

The following factors must be taken into consideration while choosing the installation

position: vessel dimensions, filling and emptying point locations, internal structure or

support and other restrictions related to vicinity to noisy devices (such as electrical motor)

and any other element which may affect the proper operation of the scanner.

IMPORTANT: When mounting the 3DLevelScanner, do not install the scanner

near the vessel wall. The installation must consider the vessel dimensions.

Installing the scanner near the side wall will result in bad performance and will not

be supported by APM.

Installing the 3DLevelscanner at the center of the vessel is not recommended, since the

perfect symmetry from all sides toward the scanner may affect the echoes distinction.

 The scanner cannot be mounted at a distance lower than 500mm (20") from the wall.

 When choosing the installation location, consider the filling and emptying points.

 Use the 3D Scanner Locator PC software for choosing a proper location.

Physical Installation ● Scanner Orientation

3.2 Scanner Orientation

Mounting direction

Mounting of the 3DLevelScanner at a specific direction is

important. The ridge on the horn body, and the notch on the

top of the thread (representing antenna no.1) should be

directed toward the center of the vessel.

Mounting direction. 0

0

indication toward vessel center

Standpipe mounting

When mounting the scanner using a standpipe part it

should be assembled and positioned at a height that

leaves at least 10mm (0.4”) out of the standpipe, for the

antenna end protrudes, as shown in the figure to the right.

IMPORTANT: Any obstruction as well

as rails, frames or support beams should

never interfere with the acoustic beam

transmitted and received, as shown in

the figure to the right.

This comment applies to all 3DLevelScanner

models including S model.

Wrong Correct

The 0

0

label location

Physical Installation ● Site Preparations

Inflowing material

Do not mount the scanners in or above the filling stream, not too

far from the stream, and not in the direction of the filling stream in

case it is diagonal, to avoid damage to the scanner from the

flowing material. The scanner should be located with a clear line of

sight to the top of the material at high levels, not to be affected by

the filling stream or the noise it creates.

Fitting

The fitting area should be prepared to maintain the

horns/antennas vertically positioned to the ground,

as shown in the figure.

Wrong Correct

3.3 Site Preparations

IMPORTANT:

The site preparations described in this section must be

complete

and

verified prior to installation. For

optimal installation, ensure that the

3DLevelScanner can be positioned and fitted according to the guidelines

described in the beginning of this chapter.

For a list of items recommended to prepare before installing the 3DLevelScanner,

refer to

page 35: Appendix D: Recommended Tools.

Before installing, make sure the following preparations have been completed.

Power

 Connecting the 3DLevelScanner chassis to the facility grounding is important for

protection.

 A 24VDC (1.5 Watt) power supply must be prepared and ready to use near the

scanner mounting location.

 The 3DLevelScanner is a 4-Wire device. The voltage supply and data output (4-

20mA) are carried along two separated two-wire connection cables.

Physical Installation ● Assembly and Mounting

Communications

 Route communication cables in proper conduits and use a proper cable type.

 The cable used for RS-485 should be of twisted-pair type, shielded, with 120 Ohm

impedance and approved for RS-485 communications.

 The cable used for 4-20mA should be rated for analog signals, twisted-pair, low

resistance and shielded.

3.4 Assembly and Mounting

Package Contents

The supplied package includes:

 3DLevelScanner sensor

 Documentation

 CD with the 3DLevel Manager software and marketing materials

 Cable glands accessory kit

 Ex-specific safety instructions (with Ex versions)

 Certificates if applicable

Included components

The 3DLevelScanner includes the following components:

3DLevelScanner Body 3DLevelScanner Head

 3DLevelScanner Body: Includes three antennas, transducers and temperature sensor.

The flange is mounted on the body and tightened to it.

 3DLevelScanner Head: Includes the electronic board with LCD display and all wiring

connections. The Head is mounted on the body.

Physical Installation ● Assembly and Mounting

Flange preparation

Prior to the installation of the 3DLevelScanner, an installation flange should

be prepared. The flange must have a 52mm (2.05”) hole for the scanner

body thread insertion.

APM provides two types of standard flanges. Please refer to page 29:

Appendix B: Accessories for flange specifications.

Installing the Flange

Verify existence of

the O-Ring on the

neck tube remains

in place as shown:

Use an adjustable 18"

wrench to untighten

and remove the nut

from the neck tube.

Place flange over the neck tube,

insert until placed as shown:

Replace the nut and tighten it over

the neck tube to the flange, using

an adjustable 18" wrench.

Make sure the

scanner is well

tightened to the

flange, for

vibrations

prevention and proper sealing.

When mounting the scanner body

and flange to the silo standpipe

make sure the scanner is facing the

center of the silo as described in

Scanner Orientation on page 9.

Installing the Scanner Head

Unpack the scanner head.

Untighten the four screws of the housing rear panel

using a 4mm hex key, and remove the rear panel. The

screws are of captive type and will not fall off.

1

2

3

4

1

Physical Installation ● Assembly and Mounting

Remove the cable clamp located at the

bottom inside the scanner as shown.

Gently insert the antenna cable through the scanner head. Make sure not to

damage the (white) cable connector. This connector connects the transmission

signal from the electronic board to the transducers. Damage to the connector or to

the wires will result with malfunctioning operation of the scanner.

Insert the scanner head onto

the neck tube.

IMPORTANT: When

inserting the scanner head

onto the neck tube, make

sure to push the head all

the way down until it fully

contacts the top of the neck tube.

NOTE: It is recommended to lubricate the O-Ring on the neck tube prior to

installing the scanne

r head. This makes it easier to insert and properly locate

the scanner head over the tube neck.

NOTE: The 3DLevelScanner head may be installed in six different positions.

Tighten the front screw using a 4mm hex key and a 13mm

wrench.

Replace the cable clamp back to

position, between the antenna cable and

the electronic board.

2

3

4

5

6

Physical Installation ● Wiring

Carefully connect the antenna cable

connector back to the electronic board as

shown.

This connector allows the transmission

signal from the electronic board to the

transducers. Damaged connector or wires

will result with malfunctioning operation of

the scanner.

Leave the scanner open at this stage in order to complete the wiring.

3.5 Wiring

The 3DLevelScanner can be connected in different modes and configurations for different

external systems such as PLC or DCS and communications on RS485, ModBus, and

HART and also to RS485 bus converting adapters to communication gateways such as

3DLinkPro for GMS or GPRS data relay and TCP/IP gateway. For in-depth details and

explanations on wiring and communication, refer to page 21: Different Connection

Methods.

 Use 8-13mm (20-24 AWG) diameter cables to ensure proper and effective sealing of

the cable gland entry opening.

 Select a cable suitable for application (indoor or outdoor) and safety certified

according to national regulations.

Communications

NOTE: If electromagnetic interference is expected, usage of a screened and

twisted wired cable

is recommended for the signal lines, which should be

connected to the ground reference.

CAUTION: Always observe the following safety instructions:

Connections must be made only in the complete absence of line voltage.

If over

-voltage is expected, overvoltage arresters should be installed.

Use only a safety

-

certified power supply with dual insulation between the primary

and output for powering the unit. The power supply output rating must be limited

to 20

-32VDC, 1A for a single 3DLevelScanner device, and

not to be connected to

a DC distribution network.

In hazardous areas you should take note of the appropriate regulations,

conformity and type of approval certificates of the sensors and power supply

units. Refer to the printed safety manual provided with the ATEX/FM approved

3DLevelScanner

.

7

8

Physical Installation ● Wiring

Power Supply

For power supply specifications, refer to page 37: Appendix E: Specifications for full

details.

4…20 mA/HART 4-wire: The power supply and signal current inputs must be carried over

two separated pairs.

Connection Procedure

Untighten the four screws of the scanner

housing rear panel

and remove the

rear panel. The

screws are of

captive type and

will not fall off.

Loosen the compression

nut of the cable gland

entry.

Insert the cable into the scanner through the cable

gland and entry opening.

Remove approximately 10cm

(4 inches) of the cable mantle

and strip approximately 1cm

(0.4 inches) the edge of each

conductor.

Open the terminal block screws located inside the

scanner housing using a thin flat (A3/32") screwdriver.

Insert the wire edges into the terminals according to the

wiring plan detailed next, and fasten the terminal

screws. Gently pull the wires to ensure they are

securely connected.

2

3

4

5

1

Physical Installation ● Wiring

Terminal block wiring plan.

The tables below describe the

connections.

Refer to the following Local Connection

and Multi-Drop Connection drawings for

details.

Left Connector

Right Connector

Ports

Description

Ports

Description

PS IN

+ -

Feed in power supply

20 – 32 VDC

RS-485

+ -

RS-485 / Modbus RTU

Communications

terminals

4...20mA

- +

4 – 20mA / HART

Communications terminals

Connect the external ground terminal with

potential equalization to the external

ground terminal of the scanner, located

as shown.

An internal cable grounding connection is also

possible using the inner connection as shown.

Tighten the compression nut over the cable gland entry opening. Verify that the

sealing ring completely wraps the cable.

IMPORTANT: Gland compression nut tightening provides good sealing.

It is necessary for the scanner to maintain IP67 requirements, and for

extended scanner lifetime.

6

7

8

Physical Installation ● Wiring

Attach the rear panel back to position at the rear of the

scanner housing and tighten the four screws to secure it in

place, using a 4mm hex key.

The 3DLevelScanner is ready for configuration.

IMPORTANT: Use direct connection between the scanners and the plant

(PLC/SCADA).

IMPORTANT: For a remote connection, use the 3DLinkPro remote connection

module or a local PC/Laptop computer as detailed in the following drawing.

CAUTION: Do not connect power supply to the 4-20mA or to the RS485 ports.

The 3DLevelScanner is not a loop powered device but a 4W device.

WARNING: The 4…20mA / HART lines should NOT be connected using

multidrop.

9

4 First-Time Activation

4.1 Local User Interface

Configuration and adjustment of the 3DLevelScanner must be done using the

3DLevelManager software, with the optional addition of GSM/GPRS communications

using 3DLinkPro. For detailed configuration procedure, refer to APM 3DLevelManager

Software Manual and the 3DLinkPro Manual.

The 3DLevelScanner User Interface

The user interface includes a 4-lines LCD display and

the four keys located on the front side of the device,

marked ESC, +, - and E.

Key functions are as follows:

Navigates back within a function menu.

Continuous 3 second press exits to the

default screen.

Navigates upwards in the navigation list.

Navigates right within a function.

Navigates downwards in the navigation list.

Navigates left within a function.

Navigates to the right when within a function group.

Stores a value once configured.

The following, simultaneous key-press combinations perform special functions as follows:

Increases / decreases the LCD display intensity.

Press and hold the

button, then use the or buttons to increase or

decrease the intensity of the display.

First-Time Activation ● Switching on the scanner

Operating menu

The operating menu consists of two levels:

 Function groups: The scanner functions are organized groups. Available function

groups are: Output Settings, Display Settings, Device Info and Device Reset.

 Functions: Each function group consists of one or more functions. The functions may

perform different actions or modify scanner setting parameters. Numerical values can

be entered, and parameters can be selected and saved.

4.2 Switching on the scanner

Once the 3DLevelScanner is connected to the power supply and switched on, it initializes

a self-test which lasts for approximately 30 seconds. When the initialization is complete,

the following content is displayed allowing selecting a language and distance units:

The unit is turned on and is initializing for

about 30 seconds, during which the display

remains blank.

The version screen appears:

The value in <> describes the scanner

model: S, M, MV or MVL.

FW Ver: Firmware version

HW Ver: Hardware version

Once the startup process is complete, the

following screen appears showing the

current distance measurement.

The forth line displays the scanner tag

name. By default, when the name has not

been configured yet, this line remains

empty.

Press

to return to the Main Menu.

Press

for 3 seconds to switch to the

basic measurement screen.

Init. Please wait...

3DLEVELSCANNER <MV>

FW Ver: 04.01.00

HW Ver: 020

Measured Parameter

3.45m Dist.

██████████████████████

test

1

2

3

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APM 3DLevelScanner II, 3DLevelScanner IIHT, 3DLevelScanner M, 3DLevelScanner MV, 3DLevelScanner S, 3DLevelScanner Series Documentation Kit

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